Hydrogen generator having a thermal actuator

ABSTRACT

A hydrogen generator having one or more actuators coupled to one or more heating elements in which the actuator(s) are used to improve the transfer of thermal energy from heating element(s) to one or more fuel units contained within the generator. In one embodiment, an actuator allows insertion and/or removal of packaged fuel units without the need of removing the heating element(s) and/or the actuator(s). When the actuator is in a retracted state (e.g., a low temperature state), the packaged fuel unit may be inserted and/or removed from a cavity of the hydrogen generator. When the actuator is in an extended state (e.g., a higher temperature state), the actuator forces contact between itself or the heating element and the fuel unit when a prescribed operating temperature is reached.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. patent application Ser. No.13/680,647 filed Nov. 19, 2012, the entirety of which is incorporated byreference as if fully set forth herein.

TECHNICAL FIELD

This invention relates to a hydrogen generator for providing hydrogengas, and more particularly to a hydrogen generator having one or morethermal actuators to improve thermal conduction between a heatingelement and one or more fuel units.

BACKGROUND

Interest in fuel cell batteries as power sources for portable electronicdevices has grown. A fuel cell is an electrochemical cell that usesmaterials from outside the cell as the active materials for the positiveand negative electrode. Because a fuel cell does not have to contain allof the active materials used to generate electricity, the fuel cell canbe made with a small volume relative to the amount of electrical energyproduced compared to other types of batteries.

In some types of hydrogen fuel cells, hydrogen is formed from ahydrogen-containing fuel supplied to the negative electrode side of thefuel cell. In other types of hydrogen fuel cells, hydrogen gas issupplied to the fuel cell from a source outside the fuel cell.

A fuel cell system can include a fuel cell battery, including one ormore fuel cells (e.g., a fuel cell stack), and a fuel source, such as afuel tank or a hydrogen generator. Hydrogen generators that supplyhydrogen gas to a fuel cell can be an integral part of a fuel cellsystem, or they can be removably coupled to the fuel cell system. Aremovable hydrogen generator can be replaced with another one when thehydrogen containing materials have been consumed. Removable hydrogengenerators can be disposable (intended for only a one-time use). Bothremovable and permanently installed hydrogen generators can berefillable (intended for use multiple times) to replace consumed fuelcomposition.

Hydrogen generators can produce hydrogen using a variety of hydrogencontaining materials and a variety of methods for initiating thehydrogen generating reactants. Hydrogen gas can be released when ahydrogen containing material is heated.

In selecting hydrogen containing materials for use in a hydrogengenerator, consideration may be given to the following: (a) stabilityduring long periods of time when the hydrogen generator is not in use,(b) ease of initiation of a release of hydrogen gas, (c) the amount ofenergy that must be provided to sustain the release of hydrogen gas, (d)the maximum operating temperature of the release of hydrogen gas, and(e) the total volume of hydrogen that can be produced per unit of volumeand per unit of mass of the hydrogen containing material(s).

Some hydrogen containing compounds can be heated to release hydrogengas, such as in a chemical decomposition reaction. Reactants that canundergo thermal decomposition reactions to produce hydrogen gas aredesirable because they generally produce a relatively high volume ofhydrogen gas on a volumetric basis.

One problem with conventional hydrogen generators is that heat transferfrom the heating element to the fuel is inefficient. Another problemwith conventional hydrogen generators is difficulty in loading fuelunits and un-loading or replacing spent fuel units.

SUMMARY

In one aspect of the invention, one or more temperature sensitiveactuators coupled to one or more heating elements are used to improvethe transfer of thermal energy from heating element(s) to one or morefuel units. In one embodiment, an actuator allows insertion and/orremoval of packaged fuel units without the need of removing the heatingelement(s) and/or the actuator(s). When the actuator is in a retracted(low temperature) state, the packaged fuel unit may be inserted andremoved from a cavity of a hydrogen generator, as discussed below. Whenthe actuator is in an extended (high temperature) state, the actuatorforces contact between itself or the heating element and a fuel unitwhen a prescribed operating temperature is reached.

In one aspect of the invention, there is provided a hydrogen gasgenerator including a housing including a plurality of sidewalls and arear wall, wherein the plurality of sidewalls and rear wall form acavity configured to receive one or more fuel units; and a heaterassembly configured to be at least partially housed within the cavity,the heater assembly including a support member configured to support atleast one heating element and at least one actuator. The at least oneactuator is in a first state when a temperature of the at least oneactuator is below a first prescribed temperature, and the at least oneactuator is in a second state when a temperature of the at least oneactuator is above a second prescribed temperature that is equal to orhigher than the first prescribed temperature. At least one of the atleast one heating element and the at least one actuator is displacedcloser in proximity to the one or more fuel units when the at least oneactuator is in the second state than when the at least one actuator isin the first state. Embodiments may include one or more of the followingfeatures:

-   -   in the second state the at least one heating element is in        conductive thermal communication with at least a portion of the        one or more fuel units;    -   in the second state the at least one actuator is in contact with        at least a portion of the one or more fuel units;    -   in the second state the at least one heating element is in        contact with at least a portion of the one or more fuel units;    -   the heater assembly is mounted to at least one sidewall of the        housing;    -   the heater assembly is mounted to the rear wall of the housing;        the heater assembly may be centrally mounted to the rear wall of        the housing, such that fuel units may be loaded or unloaded        without removing the heater assembly from the housing;    -   the hydrogen generator further includes a front panel configured        to engage the plurality of sidewalls in order to close the        housing; the heater assembly can be coupled to the front panel        and extend from an interior side of the front panel into the        cavity; when the actuator is in the second state, the front        panel may be more difficult to disengage from the plurality of        sidewalls than when the at least one actuator is in the first        state.    -   the heater assembly extends between two or more of the fuel        units;    -   the heater assembly is symmetrical along a cross-sectional plane        of the cavity;    -   at least one of the prescribed temperatures is 250 degrees        Celsius; the first prescribed temperature may be 200 degrees        Celsius and the second prescribed temperature may be 250 degrees        Celsius.

In another aspect of the invention, there is provided a hydrogen gasgenerator including a housing including a plurality of sidewalls and arear wall, wherein the plurality of sidewalls and the rear wall form acavity configured to receive one or more fuel units; and a heaterassembly including a support member configured to support at least oneheating element and at least one actuator. The at least one actuator isin a first state when a temperature of the at least one actuator isbelow a first prescribed temperature, and the at least one actuator isin a second state when a temperature of the at least one actuator isabove a second prescribed temperature that is equal to or higher thanthe first prescribed temperature. At least one of the at least oneactuator and the at least one heating element is disposed closer inproximity to the one or more fuel units when the at least one actuatoris in the second state than when the at least one actuator is in thefirst state. Embodiments may include one or more of the followingfeatures:

-   -   in the second state the at least one heating element is in        conductive thermal communication with at least a portion of the        one or more fuel units;    -   in the second state the at least one heating element is in        contact with at least a portion of the one or more fuel units;    -   in the second state, the at least one actuator is in contact        with at least a portion of the one or more fuel units;    -   the heater assembly is mounted to at least one sidewall of the        housing;    -   the heater assembly is mounted to the rear wall of the housing;        the heater assembly may be centrally mounted to the rear wall of        the housing, such that fuel units may be loaded or unloaded        without removing the heater assembly from the housing;    -   the hydrogen generator further includes a front panel configured        to engage the plurality of sidewalls in order to close the        housing; the heater assembly can be coupled to the front panel        and extend from an interior side of the front panel into the        cavity; when the actuator is in the second state, the front        panel may be more difficult to disengage from the plurality of        sidewalls than when the actuator is in the first state.    -   the heater assembly extends between two or more of the fuel        units;    -   the heater assembly is symmetrical along a cross-sectional plane        of the cavity;    -   at least one of the prescribed temperatures is 250 degrees        Celsius; the first prescribed temperature may be 200 degrees        Celsius and the second prescribed temperature may be 250 degrees        Celsius.

In another aspect of the invention there is provided a method forheating a fuel unit provided in hydrogen generator, the methodcomprising: receiving one or more fuel units in a cavity of a housing,wherein the housing includes a plurality of sidewalls and a rear wall,and the plurality of sidewalls and rear wall form the cavity configuredto receive the one or more fuel units; heating at least onetemperature-sensitive actuator above a prescribed temperature, whereinthe at least one actuator is in a first state when a temperature of theat least one actuator is below a first prescribed temperature, and theat least one actuator is in a second state when a temperature of the atleast one actuator is above a second prescribed temperature that isequal to or higher than the first prescribed temperature, and whereinthe least one actuator is disposed closer to the one or more fuel unitsin the second state than in the first state; disposing the at least oneactuator in contact with the at least one heating element; andcontacting one of the at least one an actuator and the at least oneheating element to the one or more fuel units for selectively heatingthe one or more fuel units. Embodiments may include one or more of thefollowing features:

-   -   the at least one actuator is operative to move between the first        state and the second state upon reaching one of the first and        second prescribed temperatures; the at least one actuator may        momentarily snap between first state and the second state upon        reaching one of the prescribed temperatures;    -   the actuator is a bimetallic element;    -   at least one of the first and second prescribed temperatures is        250 degrees Celsius; the first prescribed temperature may be 200        degrees Celsius and the second prescribed temperature may be 250        degrees Celsius.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a partially exploded perspective view of two fuel unitpackages;

FIG. 2A is a perspective view of an embodiment of a hydrogen generatorand fuel units for insertion therein;

FIGS. 2B and 2C are cross-section views of the embodiment illustrated inFIG. 2A;

FIG. 3A is a perspective view of an embodiment of a hydrogen generatorand fuel units for insertion therein;

FIGS. 3B and 3C are cross-section views of the embodiment illustrated inFIG. 3A;

FIG. 4A is a perspective view of an embodiment of a hydrogen generatorand fuel units for insertion therein;

FIGS. 4B and 4C are cross-section views of the embodiment illustrated inFIG. 2A;

FIG. 5A is a perspective view of an embodiment of a hydrogen generatorand fuel units for insertion therein;

FIGS. 5B and 5C are cross-section views of the embodiment illustrated inFIG. 5A;

FIG. 6 is an exemplary method in accordance with aspects of the presentinvention;

FIGS. 7A and 7B are cross-section views illustrating an exemplary layerof plaque functioning as an actuator to couple a heating element to afuel unit.

FIG. 8 is an exemplary Mica heater;

FIGS. 9 and 10 provide a perspective view and an exploded view,respectively, of a thin profile mica heater in accordance with aspectsof the present invention.

FIGS. 11 and 12 provide a perspective view and an exploded view,respectively, of a thin profile mica heater in accordance with anotheraspect of the present invention.

DETAILED DESCRIPTION

The above aspects are accomplished by a hydrogen gas generator having acavity formed within a housing of the generator and a heater assemblywithin a cavity. The heater assembly includes a support memberconfigured to support at least one heating element and at least oneactuator. The actuator is in a first state when a temperature of theactuator is below a first prescribed temperature and the actuator is ina second state when a temperature of the actuator is above a secondprescribed temperature. The heating element or the actuator is disposedcloser in proximity to one or more fuel units contained within thecavity when the actuator is in the second state than when the actuatoris in the first state.

The actuator allows slip fit of packaged fuel over a heating element foreach operator installation when the actuator is in a retracted position(i.e., a first state) and forces contact between the fuel unit and atleast one of the heating element and the actuator with the fuel unitwhen the actuator is in an extended position (i.e., a second state). Thehydrogen gas generator is particularly well suited for receiving a fuelunit package. With the actuator is the retracted position, damage to theactuator, heating element and fuel unit can be avoided during insertionand removal of the fuel unit. Any fuel unit package may be used inaccordance with aspects of the present invention.

The packaged fuel unit can be removably inserted into a hydrogen gasgenerator that can be used to provide hydrogen gas to a device, such asa fuel cell battery or other hydrogen consuming device or appliance. Thefuel unit contains a fuel composition enclosed within the package. Thefuel composition includes one or more hydrogen containing materials thatcan release hydrogen gas when heated to at least a minimum temperature.Heat from outside the fuel unit is conducted through the package toinitiate the release of hydrogen gas from the fuel composition, asdescribed below. For example, heat can be conducted from one or moreexternal heating elements (outside the fuel unit), either directly fromthe heating elements or indirectly (through the actuator(s)) via one ormore thermal conductor sections in the package. An example of a suitablefuel unit package and a method of making it is disclosed in U.S.Provisional Application No. 61/657,909, entitled “Method of Making aPackaged Fuel Unit for a Hydrogen Generator, filed Jun. 11, 2012. Thispackage includes a plurality of thermally conductive sections in apackage wall that is otherwise a relatively poor thermal conductor. Thethermal conductor sections are in thermal communication with a pluralityof segregated quantities of fuel composition, such that the release ofhydrogen gas can be selectively initiated in individual segregatedquantities, each providing a limited amount of hydrogen gas.

In the assembled fuel unit, the conductor sections in the package aredisposed to conduct heat from an external heating element through thepackage. Each conductor section can conduct heat from a separate heatingelement through the package, or heat from more than one heating elementcan be conducted through a single conductor section.

The fuel unit fuel composition includes one or more hydrogen containingmaterials that can release hydrogen gas when heated. In order toeconomically produce a large volume of hydrogen gas per unit of volumeand weight, it is advantageous to use a material that can releasehydrogen gas when heated. Such materials can produce a larger volume ofgas of reactant than, for example, the same amount (per mole, per unitof weight or per unit of volume) of reactants that undergo a hydrolysisreaction. Preferred materials do not require costly catalysts to undergohydrogen-generating reactions.

The fuel composition contains at least one hydrogen containing material.More than one hydrogen containing material can be included. Examplesinclude materials that can reversibly absorb and desorb hydrogen (e.g.,metal-organic frameworks (MOFs), zeolites, graphene, carbon nanotubesand metal hydrides as AB₅ and AB₂ type hydrogen storage alloys such astitanium-manganese, mischmetal-nickel, lanthanum-nickel-cobalt andlanthanum-nickel alloys), materials that can react to produce hydrogengas upon thermal decomposition (e.g., metal hydrides such as lithiumhydride, magnesium hydride, and aluminum hydride (alane), complexhydrides and their ammonia adducts such as lithium borohydride, sodiumborohydride, magnesium borohydride, calcium borohydride, ammine titanium(III) borohydride, lithium aluminum hydride, sodium aluminum hydride,lithium amide, and calcium aluminum hydride, and B—N chemical hydridessuch ammonia borane and hydrazine borane), and various combinationsincluding the above materials. Choices of materials may be limited byother factors such as physical and chemical properties of the material,the type and location of heating elements, the temperature range for thedesired release of hydrogen gas, whether the hydrogen release isexothermic or endothermic, the composition, form and properties ofbyproducts, and so on.

The fuel composition can also contain one or more additives. Examples ofadditives include binders (e.g., acrylates and styrene blockcopolymers), stabilizing compounds (e.g., solid bases), thermallyconductive materials (e.g., metals, graphites and combinations andcomposites thereof), ignition materials as described below, thermallyconductive coatings or layers, thermally insulating coatings or layers,and so on. Preferably catalysts are not included in the fuelcomposition.

It may be desirable to include an ignition material in the fuel unit,especially if the release of hydrogen gas is endothermic. An ignitionmaterial reacts exothermically when heated and can be used inconjunction with the initiation system to provide heat to initiate therelease of hydrogen gas from the hydrogen containing material. Anignition material can provide a number of advantages. The temperature towhich the ignition material must be heated to react may be lower thanthe minimum temperature to which the hydrogen containing material mustbe heated, reducing the heat producing requirement for the initiationsystem. Because the ignition material reacts exothermically, it canreduce the total amount of energy that must be supplied to the heatingelements during use of the fuel unit, particularly if the release ofhydrogen gas by the hydrogen containing material is endothermic. Anignition material can be disposed within or in contact with the fuelcomposition. For example, the ignition material can be an ingredient ofthe fuel composition, the ignition material can be a separate layer ofthe fuel composition from the portion containing the hydrogen containingmaterial, or ignition material can be in a separate pellet in thermalcommunication with the fuel composition. When an ignition material isseparate from the hydrogen containing material, portions containingignition material can be alternated with portions containing hydrogencontaining material. For example, each portion containing hydrogencontaining material can have an adjacent portion of ignition material; aportion containing ignition material can be disposed adjacent tomultiple portions of fuel composition. If desired, ignition material canbe proximate a surface of the fuel unit to facilitate initiation by anexternal heating element. A portion of ignition material can extend awayfrom the point of initiation to facilitate heating fuel composition inremote portions of the fuel unit. In some embodiments, both the portioncontaining hydrogen containing material and the portion containingignition material contain both hydrogen containing and ignitionmaterials, but in different proportions. Some types of ignitionmaterials will also generate hydrogen gas when they react, contributingto the total amount of hydrogen the fuel unit can provide. Examples ofignition materials include metal/metal oxide multilayers such asTi/Pb₃O₄, Zr/Fe₂O₃, guanidinium borohydride, B—N compounds blended withoxidizers such as ammonium nitrate or Sr(NO₃)₂ as described inUS2011/0027168A1, metal/metal multilayered thin films and structuressuch as Ni/Al as described in U.S. Pat. No. 7,867,441, autoignitioncompositions such as silver nitrate mixed with potassium nitrate andmolybdenum metal as described in U.S. Pat. No. 6,749,702, complexhydride, oxidizer, and S compositions such as described in U.S. Pat. No.7,964,111, and the compositions described in patents US2008/0236032A1and US 2008/0241613A1. Other compositions include gels of metals andwater such as Mg/water/poly(acrylamide-co-acrylic acid) alone or incombination with sodium borohydride (Varma, et al. Chem. Eng. Sci 2010,65, 80-87 and Int. J. Hydrogen En 2007, 32, 207-211, respectively). Itwill be understood that references herein to initiating a release ofhydrogen gas from a hydrogen containing material includes initiating aheat generating reaction in an ignition material in embodiments in whichthe fuel unit includes an ignition material.

The fuel composition is preferably a high density solid, rather than agas, liquid or gel. A solid fuel composition can be in any suitableform, such as in powdered or granular form (e.g., contained in one ormore compartments), or formed into solid bodies such as pellets, pills,tablets, wafers or cakes, e.g., by compressing, molding extrudingdepositing, coating roll coating, printing, and so on. The fuelcomposition can be in contained within one or more receptacles or formedon a substrate. Each fuel unit can have a single quantity of fuelcomposition, or the fuel composition can be disposed in one or moresegregated quantities. Quantities of fuel composition can be sized andshaped to produce a desired amount of hydrogen gas, fit within the fuelunit in a volume efficient manner, facilitate initiation (heating),prevent cross-initiation of adjacent quantities, facilitate release ofgenerated hydrogen, and so on.

Segregated quantities of fuel composition can be separated from oneanother in various ways, such as by containment in individualcompartments and/or being spaced apart by gaps, coatings, thermalinsulation and the like. If the fuel composition is contained in one ormore compartments, the compartments may be covered with a covering layerto retain the material in the desired compartments. The compartments andthe covers can be part of the fuel unit package.

The fuel unit package contains the fuel composition as well asnon-gaseous byproducts. The package will have sufficient strength andchemical and thermal stability to do so during shipping, during storageand handling prior to use, during use, and during removal and subsequenthandling. The package can be made from a variety of materials, such asmetal foil, polymer film, laminates such as metal/plastic laminates, andcast or molded casings. Examples of metal/plastic laminates includemetals such as aluminum, nickel, copper and steel and polymers such aspolyesters, nylons, polypropylene and polyethylene. High temperatureplastics and thermosets can be used to cast or mold casings; examplesinclude polyimides such as KAPTON® (from DuPont) and polyether etherketone (PEEK) polymers. The package can be closed by any suitable methodor methods, such as by folding and/or overlapping, mechanically closing,sealing (e.g., with an adhesive, heat seal, ultrasonics) and so on. Itmay also be desirable for the package to remain sealed except to releasehydrogen as needed. This can require sealing the package, the use of ahydrogen outlet valve and/or the capability of containing at least someinternal pressure for example. Sealing the package can protect thecontents from exposure to the environment (e.g., from oxygen andmoisture), contain small quantities of hydrogen that may be producedbefore the fuel unit is used and facilitate removal of contaminants fromthe hydrogen gas before it is released from the fuel unit.

It may be desirable to include thermal insulation near or as part of thepackage to protect the user when a used fuel unit is removed from thehydrogen generator. The package itself may be or include (e.g., as alayer thereof) a poor thermal conductor, or a layer of thermalinsulation can be provided external or internal to the package. Examplesof materials that may be suitable as thermal insulation include silica,silicon dioxide, silicon nitrides, silicon carbide, silica aerogel,calcium silicate, foamed silicone, alumina, aluminum oxide, glass, glasswool, mineral wool, cellular glass, perlite, and elastomers and polymerssuch as polyimides and epoxy-amine composites.

It may be desirable to include thermal conductors within the fuel unitto provide good heat transfer to remote portions of the fuel composition(portions that are not close to the package or to the heaters). Asdescribed above, additives may be included in the fuel composition forthis purpose, or thermally conductive components can be included withinthe fuel unit. Heating efficiency can also be enhanced by applying heatto a recessed portion of the fuel unit package, such as a hollow core ofthe fuel unit, rather than to an outer surface (e.g., an outsidediameter) of the fuel unit because heating from the inside of the fuelunit will result in less parasitic heat loss than heating from theoutside of the fuel unit. A similar effect can be accomplished bylocating internal heaters away from the outer surface of the fuel unit.

Fuel units can be used in a hydrogen generator in which the fuelcomposition in a fuel unit is heated to produce hydrogen gas. Thehydrogen gas can be used by a hydrogen consuming apparatus, such as ahydrogen fuel cell battery. The hydrogen generator can be made byproviding and assembling: a housing with one or more cavities forremovably containing one or more fuel units, one or more heatingelements, each configured to heat a portion of the fuel composition inthe fuel unit(s) to at least a minimum temperature, an energy source,electric circuitry for supplying electric current to the heatingelement(s), and one or more fuel units, which are removably insertedinto the one or more cavities. As described in more detail below, theone or more heating elements may be coupled to one or more actuators inorder to place the heating element or the actuator in direct contactwith the fuel units. Preferably, the one or more actuators aretemperature-sensitive.

Preferably the hydrogen generator is portable, either alone or as partof a hydrogen consuming apparatus, such as part of a fuel cell systemincluding a fuel cell battery or contained within a portable device thatcan be powered by a fuel cell system. As used herein, portable meansreadily moved by an individual person, without requiring the use oflifting or transporting equipment (e.g., a hoist, dolly, lift truck orthe like).

In order to provide an economical hydrogen generator, it is desirable tobe able to replace spent fuel composition (e.g., reaction byproducts)with fresh fuel composition, rather than replacing the entire hydrogengenerator. This allows durable components of the hydrogen generator tobe used many times. To maximize this effect, it is desirable toincorporate as many reusable components as practical into the reusableportion of the hydrogen generator (referred to below as the holder), therest of the fuel cell system and/or the device associated with the fuelcell system, and to limit the number of components in the replaceableportion of the hydrogen generator (referred to below as the fuel unit)to the greatest extent practical. This is particularly true for suchitems that occupy a relatively large volume and/or are relativelyexpensive. Ideally, fuel units would contain only the hydrogencontaining materials and minimal packaging. However, for practicalreasons it may also be desirable to include other ingredients andcomponents in the fuel units.

The hydrogen generator can include a holder that is configured toreceive one or more fuel units. It can contain at least some of theother components of the hydrogen generator. In some circumstances, itmay be desirable to locate at least portions of other components outsidethe holder, such as elsewhere within the fuel cell system and/or device.The holder can include a housing of its own, particularly if the holderis intended to be removed from or used while outside the rest of thefuel cell system or device. A separate holder housing may not be desiredif the hydrogen generator is contained within the fuel cell systemand/or device. For example, a portion of the fuel cell system or devicecan serve as all or part of a holder housing. The holder housing hassufficient mechanical strength and resistance to the environment towhich the hydrogen generator is expected to be exposed, particularly tohigh temperatures and hydrogen containing materials and byproductsassociated with the release of hydrogen gas. Metals such as aluminum,steel and stainless steel, ceramics, and high temperature resistantpolymers such as polyphenylene sulfide, acrylonitrile butadiene styrene,polyetheretherketone, polyetherimide, polyoxybenzylmethylenglycolanhydride (Bakelite®), epoxies, phenolics, diallyl phthalate andmelamine may be suitable for the housing. In some embodiments the holdermay be made from a material that is a poor thermal conductor (e.g., lessthan 10 watts/meter·Kelvin), and preferably less than 1watt/meter·Kelvin) to protect the rest of the fuel cell system, thedevice and/or the user from heat produced within the hydrogen generator.If desired, thermal insulation can be added to the hydrogen generator,within the housing, around the housing or elsewhere in the fuel cellsystem or the device. A vacuum, such as in a hollow space in a wall(s)of the holder, can provide thermal insulation. Thermal insulation canprotect components of the hydrogen generator, other parts of the fuelcell system, the device with which the fuel cell system is being used,and/or the user.

The hydrogen generator includes one or more cavities into which one ormore fuel units can be removably inserted. The hydrogen generator caninclude features for aligning the packaged fuel unit in a particularorientation, providing thermal and/or electrical contact with the fuelunit, and/or providing a hydrogen gas flow path between the holder andthe fuel unit. For example, walls defining the cavity can include one ormore projections that cooperate with features of the fuel unit to permitinsertion of a fuel unit into the cavity in only the desiredorientation, projections can provide electrical and/or thermal contactwith the fuel unit, or one or more projections can extend into arecessed area of the fuel unit to provide heating from the inside of thefuel unit outward. The hydrogen generator can be closable to retain thefuel unit within the cavity, and it may be sealable to exclude gasesfrom the outside environment and to contain pressurized hydrogen gas. Ifinternal pressure can build up during operation of the hydrogengenerator, it may be desirable to include a pressure relief vent torelease gas before the pressure becomes excessive (i.e., to preventundesired opening or bursting of the housing).

Hydrogen gas produced in the fuel unit exits the fuel unit and thenexits the hydrogen generator through a hydrogen flow path to an outletthat interfaces with the rest of the hydrogen consumint (e.g., fuelcell) system. The hydrogen generator can include various fittings,valves and electrical connections for providing hydrogen to andinterfacing with a fuel cell battery and/or an electrical device beingprovided with power by the fuel cell system. It may be desirable toprovide one or more filters or purification units (referred to asfilters below) in the hydrogen flow path to remove solid or gaseousbyproducts (such as fuel cell poisons) and/or unreacted fuel compositionfrom the hydrogen gas. Filters can be located within the fuel units,within the holder and/or at the interface between the hydrogen generatorand the rest of the fuel cell system. Filters within the fuel units arereplaced when the fuel units are replaced. It may be desirable toprovide access for periodically replacing filters located outside thefuel units. Examples of materials that may be suitable for filtersinclude silica, silicon dioxide, silicon nitrides, silicon carbide,silica aerogel, alumina, aluminum oxide, glass, glass wool, mineralwool, cellular glass, microfiberglass, perlite and polymers such aspolytetrafluoroethylenes, polyimides and epoxy-amine composites, as wellas suitable gas purification units (such as ion exchange resins). It maybe possible to position filters so they also provide thermal insulation.

The hydrogen generator includes one or more heating elements forconverting electric energy to thermal energy that can provide heat forreleasing hydrogen gas from the hydrogen containing material in the fuelunit. Examples of suitable energy sources include one or a combinationof a primary battery, a secondary battery, a fuel cell battery, acapacitor and a public utility. The energy source is preferable outsidethe fuel unit, such as in the holder, elsewhere in the fuel cell system,in the device, or external to the device. Circuitry in the hydrogengenerator and/or the fuel unit can carry the electric energy to theheating element(s) and/or the actuator(s). The heating elements areoutside the fuel unit (e.g., in the holder), where they can be reused.The heating element can be a resistive heater. Any suitable resistiveheater can be used, such as a resistive heater including metals oralloys such nickel-chromium, iron-chromium-aluminum and copper-nickel.Another exemplary heating element includes a thin profile mica heater,as discussed below. An external heater heating element will be inthermal contact with a thermally conductive sections in the fuel unitpackage such that heat produced by the heating element is conductedthrough the package to the contents of the fuel unit. To provide goodthermal contact, the fuel unit package can fit snugly against the heateror an intermediate thermal conductor, such as an actuator. The heater orintermediate thermal conductor can be biased against the conductorsection. This can be accomplished by configuring the heating element asa biasing member and/or by placing an intermediate biasing member thatis a good thermal conductor in thermal contact between the heatingelement and the fuel unit package conductor section through theactuator. The use of a biasing member can provide good thermal contactbetween the heating element and the fuel unit without impeding insertionor removal of the fuel unit into and from the cavity and can compensatefor expansion or contraction of the fuel unit during use.

As described in further detail below, multiple heating elements can beused to provide the capability of selectively heating limited quantitiesof the total amount of hydrogen containing material in one or more fuelunits. This can be helpful in generating hydrogen gas on an as neededbasis and minimizing response times during intermittent use, withoutcreating excessive pressure within the hydrogen generator. For example,individual heating elements can be associated with segregated quantitiesof fuel composition within a fuel unit, and operation of selectedheating elements can be controlled to initiate the release of hydrogengas within only the desired quantities of fuel composition. This canrequire alignment of conductor sections in the fuel unit package withindividual heating elements or electrical contact terminals in thehydrogen generator outside the fuel unit. As an alternative, a heatingelement can be moved within the cavity to align with selected conductorsections of the fuel unit package. This can provide controlledgeneration of hydrogen gas with fewer heating elements, but addingvolume and cost for the mechanism necessary to move the heating element.

It has been discovered that the closer the heating element or athermally conductive element is to the fuel unit, the more efficientthermal conduction will be. Testing has revealed that heat transfer fromthe heating element to the fuel unit is not efficient when heatingelement to fuel unit contact is poor (e.g., the larger the space betweenthe heating element and the fuel unit, the more inefficient thermalconduction becomes). Efficiency of heating the fuel unit reducesparasitic losses, which will allow the packaged fuel to be smaller andless expensive, for example.

In order to improve thermal efficiency, an actuator is provided thateffectively moves the heating element closer to the fuel unit or enablesconductive thermal communication between the heating element and thefuel unit. The conductive thermal communication provides conduction ofheat either directly from the heating element or indirectly from theheating element, through the actuator, to the fuel unit. In this wayheat is efficiently delivered to the fuel unit. The actuator may be anydesired actuator. Preferably, the actuator allows insertion and removalof the one or more fuel units into and from the cavity (or cavities)without removal of the heating element(s) or the actuator. In addition,it also desirable that the actuator be thermally activated.

The actuator may go through a transition between the first and secondstates, in which the actuator and/or the heating element is neitherfully retracted nor fully expanded, with the actuator being in atransitional state when its temperature is between the first and secondprescribed temperatures, or the change between first and second statescan be essentially immediate (i.e., no more than about 5 seconds), withthe first and second prescribed temperatures being essentially equal. Insome embodiments the change from the first state to the second state canbe at temperature that is higher than the temperature at which thechange from the second state to the first state occurs, whether theactuator goes through a transitional state or not.

In one embodiment, the actuator immediately changes from the first stateto the second state or from the second state to the first state upon aprescribed temperature being reached. Such action may be referred as“snap action”, where the actuator is stable only in the first state orthe second state, and the time between reaching the first state andsecond state is no more than about 5 seconds. For example, the actuatormay change from the first state to the second state when actuatortemperature reaches 250 degrees Celsius. The actuator may change fromthe second state to the first state when the actuator temperaturereaches 200 degrees Celsius.

An exemplary actuator is a bimetallic element. A bimetallic element is adevice formed of two metals that are bonded together, each having adifferent coefficient of thermal expansion. A bimetallic element is usedto convert a temperature change into mechanical displacement. Inparticular, the actuator is in a first (retracted) state when atemperature of the actuator is below a first prescribed temperature andthe actuator is in a second (extended) state when a temperature of theactuator is above a second prescribed temperature. Such an actuatorprovides an efficient and reliable means of transferring thermal energyfrom the heating element to the fuel unit. The bimetallic elements maytake any desired form. For example, the bimetallic elements may includeone or more discs or Z-folded elements. The size and shape of thebimetallic materials may vary based on the application, the fuel unitand/or the heating element.

Another exemplary actuator is a layer of plaque made up of from apositive temperature coefficient (PTC) composition that includes acarbon and polymer blend, may be used to join the heating elements tothe fuel unit. The PTC composition expands during heating. The layer ofplaque is used to join the heating elements to the conductor sectionswhen the fuel are inserted in the cavity and the layer of plaque isheated to a temperature sufficient to activate the PTC composition.

The heater assembly is configured to be at least partially housed withinthe cavity. The heater assembly includes a support member configured tosupport at least one heating element and at least one actuator. Theactuator is in a first state when a temperature of the actuator is belowa first prescribed temperature and the actuator is in a second statewhen a temperature of the actuator is above a second prescribedtemperature. At least one of the heating element and the actuator isdisposed closer in proximity to the fuel units when the actuator is inthe second state than when the actuator is in the first state. Thus, theactuator may be used to place the heating element in direct contact withthe fuel unit, or the actuator, which is thermally conductive, may bebetween the heating element and the fuel unit, in direct contact withboth, so that it is able to conduct heat from the heating element to thefuel unit.

One advantage of using the actuator described above is that in the firststate, when the actuator temperature is below a first prescribedtemperature, the actuator is in a retracted state. Such a state enablesan user to easily remove and/or replace spent fuel units, as well asinsert new fuel units, without removing components of the hydrogengenerator (e.g., the heating elements).

The mounting of the heater assembly to the hydrogen generator may take avariety of forms. For example, the heater assembly may be secured to astructure of the housing. The heater assembly may be secured to the rearwall of the one or more cavities, one or more sidewalls of the one ormore cavities and/or to a front panel, which effectively seals thecavity and provides access for a user to insert and/or remove fuelunits. Preferably, the heater assembly is configured for permanentpositioning within the cavity. The heater assembly may also include afastening mechanism that enables the heater assembly to be removed, attimes, for maintenance, for example. The heater assembly may use anydesired fastening mechanism to secure the heater assembly to thehousing.

In one embodiment, the actuator is configured to be secured to astructure within the cavity. As described above, such a structure mayinclude: a rear wall, a sidewall, and/or a front panel of the housing.Any number of actuators may be used in conjunction with a particularfuel unit. In one embodiment, a single actuator element is coupledbetween the structure of the cavity and the heating element. In anotherembodiment, a plurality of actuators are coupled between the structureof the cavity and the heating element. In yet another embodiment, asingle actuator element may be coupled between the structure of thecavity and a plurality of heating elements. In another embodiment, thenumber of actuators is the same as the number of conductive regions onthe packaged fuel unit.

In another embodiment, the one or more heater elements are configured tobe secured to a structure within the cavity. As described above, such astructure may include: a rear wall, a sidewall, and/or a front panel ofthe housing. Any number of heater elements may be used in conjunctionwith a fuel unit. In one embodiment, a single heater element is coupledbetween the structure of the cavity and the actuator. In anotherembodiment, a plurality of heating elements are coupled between thestructure of the cavity and the actuator. In yet another embodiment, asingle heating element may be coupled between the structure of thecavity and a plurality of actuators. In another embodiment, the numberof actuators is the same as the number of conductive regions on thepackaged fuel unit.

In another embodiment, the heater assembly is coupled to the front paneland extends from the interior side of the front panel into the cavity.The heating elements and the actuator may be secured on the both sidesof the heater assembly or on a single side of the heater assembly. Theheating element may be secured between the heater assembly and theactuator or the actuator may be secured between the heater assembly andthe heating element. In such an embodiment, it is preferable for theheater assembly to be inserted between a plurality of fuel units.

The structures set forth above are robust and provide a convenientmechanism for loading and/or removing fuel units from the cavity in awide range of applications. This is accomplished by the dual statenature of the actuator. For example, when a temperature of the actuatoris below a first prescribed temperature the actuator in a first state(e.g., a retracted state) and the actuator is in a second state (e.g.,an extended state) when a temperature of the actuator is above a secondprescribed temperature. In the first state, one or both the heatingelement and the actuator are disposed farther from the fuel unit thanwhen the actuator is in the second state, leaving a gap between the fuelunit and the heating element and actuator. In the second state, theheating element or the actuator is in direct and thermal contact withthe fuel unit.

In order to provide hydrogen gas on an as-needed basis withoutdeveloping a high internal pressure within the hydrogen generator, itmay be advantageous for the hydrogen generator to include multiple fuelunits, each of which that can be used selectively, and/or for the fuelunit(s) to contain multiple segregated quantities of fuel composition inwhich the release of hydrogen gas can be individually initiated on aselective basis. This can be accomplished by using a control system inconjunction with multiple heating elements and/or a moveable heatingelement that can be located within or aligned with individual segregatedquantities of fuel composition in the fuel unit(s).

A control system can be used to control the supply of energy from asource to the heater assembly. The control system can determine the needfor hydrogen and/or the required hydrogen flow rate by monitoring thepressure within the hydrogen consuming (e.g., fuel cell) system, one ormore electrical characteristics of the fuel cell battery, or one or moreelectrical characteristics of the electronic device, for example. Thecontroller may communicate with the device or the fuel cell battery todetermine when more hydrogen is needed. The control system can becompletely or partially disposed in the hydrogen generator, the fuelcell battery, the electronic device being powered by the fuel cellbattery, or any combination thereof. The control system can include amicroprocessor or microcontroller; digital, analog and/or hybridcircuitry; solid state and/or electromechanical switching devices;capacitors, sensing instrumentation, timers and so on. The same or adifferent control system can also be used for other purposes, such asidentifying hydrogen generators and fuel units that are appropriate orapproved for use, preventing use of inappropriate or unapproved hydrogengenerators and fuel units, controlling charging of batteries in the fuelcell system and the device by the fuel cell battery, calculating andproviding information on the remaining capacity of the fuel unit(s),recording historical information regarding the use of fuel units, thehydrogen generator, the fuel cell system and the device, preventingoperation of the hydrogen generator under unsafe conditions, and otherpurposes.

In an embodiment of a hydrogen generator, an access panel can be securedto the housing to enclose the fuel unit(s) in the cavity with aninterlock mechanism. The interlock mechanism retains the access panel inplace when an internal temperature of the hydrogen generator exceeds aprescribed temperature but allows opening or removal of the access panelwhen the temperature is at or below the prescribed internal temperature.The interlock mechanism can thus prevent removal of a fuel unit from thehydrogen generator while the fuel unit is hot enough to cause personalinjury to a user or damage to materials with which it may subsequentlycome in contact.

FIG. 1 shows two packaged fuel units 60, one of which is shown explodedso internal components are visible. The fuel units 60 are positionedwith packaging strips 46 facing each other. Each packaging strip 46includes a substrate 10 with apertures 12 covered by conductor sections22. Each of the fuel units 60 is shown in FIG. 1 with external thermalinsulation 62 surrounding all sides except the sides covered by thepackage strips 46. In some embodiments the fuel units 60 can beconnected to each other, such as along one edge. They can beinterconnected by one or any combination of their containers 52, packagestrips 46, external thermal insulation 62, or some other component (notshown). If the fuel units 60 are interconnected, they can be spacedapart, and if the interconnection is at least somewhat rigid, spacingcan be maintained between the fuel units 60, such as to accommodate aheater assembly between the fuel units 60. The fuel unit 60 can includea hydrogen gas outlet 66 and a filter 64 between the quantities of fuelcomposition 54 in a plurality of compartments 56 and an outlet 66 (e.g.,by attaching a filter membrane to the outlet 66 or the container 52).

An embodiment of a hydrogen generator is shown in FIGS. 2A-2C. Thehydrogen generator 70 includes a housing 72, with a cavity 74 into whichpackaged fuel units 60 can be inserted. The hydrogen generator 70includes a door 76 for closing and sealing the housing 72 with the fuelunits 60 inside. Two rectangular fuel units 60, each containing threesegregated quantities of fuel composition 54 are shown, but fewer ormore fuel units with the same or different shapes and the same or adifferent number of quantities of fuel composition 54 can be used. Thehydrogen generator 70 further includes at least one heater assembly 78with one or more heating elements 80 and actuators 100 (see FIGS. 2B,2C) supported by a support member 82. The heating elements 80 may becoupled to the support member 82 by one or more actuators 100. Theactuators 100 are preferably one or more thermal actuators (e.g., abimetallic element) that are in a first state when the actuatortemperature is below a first prescribed temperature and in a secondstate when the actuator temperature is above a second prescribedtemperature. Referring to FIG. 2B, the actuator 100 is illustrated inthe first state. In the first state, the heater assembly 78, along withthe heating elements 80 and the actuators 100, is configured to bereceived between the rectangular fuel units 60. Referring to FIG. 2C,the actuator 100 is illustrated in the second state. In the secondstate, the actuator temperature is above a second prescribed temperatureand the actuator 100 is in an extended state, which forces the heatingelements 80 to make contact with the fuel units 60. Preferably, theheating elements 80 will make contact with corresponding conductorsections 22 when the fuel units 60 are disposed in the cavity 74 and theactuators 100 are in the second state.

Another embodiment of a hydrogen generator is shown in FIGS. 3A-3C. Thehydrogen generator 70 of FIGS. 3A-3C is identical to the hydrogengenerator of FIGS. 2A-2C, except that the heating elements 80 arecoupled to a support member 82. One or more actuators 100 may then becoupled to the support member 82 as illustrated in FIGS. 3A-3C.Referring to FIG. 3B, the actuators 100 are illustrated in the firststate. In the first state, the heater assembly 78, including the heatingelements 80 and the actuators 100, is configured to be received betweenthe fuel units 60. Referring to FIG. 3C, the actuator 100 is illustratedin the second state. In the second state, the actuator temperature isabove a second prescribed temperature and the actuators 100 are in anextended state. Thermal energy is transferred from the heating elements80 and through the actuators 100, which are in contact with the fuelunit 60. Preferably, the actuators 100 will make contact withcorresponding conductor sections 22 when the fuel units 60 are disposedin the cavity 74 and the actuators 100 are in the second state.

In another embodiment, illustrated in FIGS. 4A and 5A, the heaterassembly 88 includes heating elements 80 that can be attached to thehousing 72 (e.g., a sidewall, rear wall, etc.) and optionally anintermediate support member 92 through an actuator 100 (as illustratedin FIGS. 4A-4C), or the heater assembly 88 can be attached to thehousing 72 and further include an actuator 100 coupled to the supportmember 92 (as illustrated in FIGS. 5A-5C). When the heater assembly 88is attached to the side walls or rear wall of the housing 72, as shownin FIGS. 4A and 5A, it may be desirable for support member 92 to be athermal insulation member, projecting inward from the door 76 to providethermal separation between the fuel units 86.

Referring to FIGS. 4A-4C, the hydrogen generator 84 further includes atleast one heater assembly with one or more heating elements 80 each. Theheating elements 80 may be coupled to the support member 90 or housing72 by one or more actuators 100. The actuator 100 is preferably athermal actuator (e.g., a bimetallic element) that is operable in afirst state when the actuator temperature is below a first prescribedtemperature and operable in a second state when the actuator temperatureis above a second prescribed temperature. When the actuator temperatureis in the first state, the fuel units 86 may be easily inserted and/orremoved from the cavity 74. When the hydrogen generator 84 is in thesecond state and the actuator temperature is above the second prescribedtemperature, the actuator 100 is extended and forces the heating element80 to contact the fuel unit 86.

Referring to FIG. 4B, the actuator(s) 100 are illustrated in the firststate. In the first state, the heater assembly 88, including the heatingelements 80 and the actuators 100, is configured allow easy insertionand/or removal of the fuel units 86 within the cavity 74. Referring toFIG. 4C, the actuators 100 are illustrated in the second state. In thesecond state, the actuator temperature is above a prescribed secondtemperature and the actuators 100 are in an extended state, which forcesthe heating elements 80 to make contact with the fuel units 86.Preferably, the heating elements 80 will make contact with correspondingconductor sections 22 when the fuel units 86 are disposed in the cavity74 and the actuators 100 are in the second state.

Another embodiment of a hydrogen generator is shown in FIGS. 5A-5C. Thehydrogen generator 84 of FIGS. 5A-5C is identical to the hydrogengenerator 84 of FIGS. 4A-4C, except that the heating elements 80 may becoupled to the housing 72 (e.g., a sidewall, rear wall, etc.) oroptionally to an intermediate support member 90. One more actuators 100may be coupled to heating elements 80, such that the one or moreactuators 100 can transfer thermal energy emitted by the heatingelements 80 to the one or more fuel units 86. The actuators 100 arepreferably thermal actuators (e.g., bimetallic elements) that are in afirst state when the actuator temperature is below a first prescribedtemperature and in a second state when the actuator temperature is abovea second prescribed temperature. When the actuator temperature is belowthe first prescribed temperature, the fuel units 86 may be easilyinserted and/or removed from the cavity 74. When the actuatortemperature is above the second prescribed temperature, the actuator 100is extended and makes contact with the fuel unit 86. Preferably, theactuators 100 will make contact with corresponding conductor sections 22when the fuel units 86 are inserted in the cavity 74 and the actuators100 are in the second state.

Referring to FIG. 5B, the actuators 100 are illustrated in the firststate. In the first state, the heater assembly 88, including the heatingelements 80 and the actuators 100, is configured to allow easy insertionand/or removal of the fuel units 86 within the cavity 74. Referring toFIG. 5C, each actuator 100 is illustrated in the second state. In thesecond state, the actuator temperature is above a second prescribedtemperature and the actuator 100 is in an extended state, which forcesthe actuator 100 to make contact with the fuel unit 86. Preferably, theactuator 100 will make contact with corresponding conductor sections 22when the fuel unit 86 is disposed in the cavity 74 and the actuator 100is in the second state.

The heater assemblies 88 can be on an inner surface of the door 76 or aninner surface of the housing 72 (e.g., the side walls and/or rear wall),such that the heating elements 80 or the actuators 100 will make contactwith corresponding conductor sections 22 when the fuel units 86 areinserted in the cavity 74 and the actuators 100 are in the second state.Alternatively, the heater assemblies 88 can be on a support member 92extending from the door 76 (as shown in FIG. 2A) or from the housing 72,such that heating elements 80 or the actuators 100 will make contactwith corresponding conductor sections 22 when the fuel unit(s) 86 areinserted in the cavity 74 and the temperature is above the secondprescribed threshold. By centrally locating the heater assembly 78, thefuel units 86 are substantially heated from the inside out.

In the embodiments illustrated in FIGS. 4A-4C and 5A-5C, the hydrogengenerator 84 includes a housing 72, with a cavity 74 into which packagedfuel units 86 can be inserted. The hydrogen generator 84 includes a door76 for closing and sealing the housing 72 with the fuel units 86 inside.Four triangular fuel units 86 with one quantity of fuel composition 54each are shown. Different shapes and numbers of fuel units withdifferent numbers of quantities of fuel composition can be used. Asdiscussed above, the hydrogen generator 84 includes at least one heaterassembly 88 with one or more heating elements 80 and one or moreactuators 100. The heater assembly 88 can be attached to the door 76, asshown in FIG. 3, or to the housing 72. Heating assemblies 88 can be onan inner surface of the housing 72 (as shown) or door 76, such that theheating elements 80 will make contact with corresponding conductorsections 22 when the fuel units 86 are inserted in the cavity 74.Alternatively, the heater assemblies 88 can be on a support member 82extending from the door 76 (as shown) or from the housing 72, such thatheating elements 80 will make contact with corresponding conductorsections 22 when the fuel units 86 are inserted in the cavity 74.

An exemplary method 110 for heating a fuel unit provided in a hydrogengenerator is illustrated in FIG. 6. At block 112, the method includesreceiving one or more fuel units in a cavity of a housing, wherein thehousing includes a plurality of sidewalls and a rear wall, and whereinthe plurality of sidewalls and rear wall form the cavity configured toreceive the one or more fuel units.

At block 114, at least one temperature-sensitive actuator is heatedabove a prescribed temperature. The actuator is in a first state when anactuator temperature is below a prescribed temperature (e.g., a firstprescribed temperature of less than 200 degrees Celsius) and in a secondstate when an actuator temperature is above a prescribed temperature(e.g., a second prescribed temperature above 250 degrees Celsius),wherein the least one actuator has an extended state in the secondstate.

At block 116, a heating element coupled to the actuator and/or thetemperature-sensitive actuator is coupled to the one or more fuel unitsfor selectively heating the one or more fuel units. The actuator movesbetween the first state and the second state upon reaching a prescribedtemperature (e.g., the second prescribed temperature). The actuatormomentarily snaps between first state and the second state upondetecting the prescribed temperature. The actuator can be a bimetallicelement. The bimetallic element extends in a first direction and asecond opposing direction, illustrated in FIGS. 2B, 2C, 3B, 3C, 4B, 4C,5B and 5C.

In another embodiment, illustrated in FIGS. 7A-7B, a layer of plaque102, made up of from a positive temperature coefficient (PTC)composition that includes a carbon and polymer blend, may be used as anactuator. The PTC composition expands during heating. FIG. 7Aillustrates the layer of plaque 102 in the first state; and FIG. 7Billustrates the layer of plaque 102 extended to the second state. Thelayer of plaque 102 is used to join the heating elements 80 to theconductor sections 22 when the fuel units 86 are inserted in the cavity74 and the cavity 74 is heated to a temperature sufficient to activatethe PTC composition.

Commercial mica heaters are capable of operating at the temperaturesrequired for a thermolysis fuel cartridge, but the mechanism used toclamp them together tends to be thick (e.g., not volume efficient). Highenergy volume ratios are needed for successful commercialization ofthermolysis fuel cartridges. Mica heaters must be clamped together priorto powering and remain clamped from that point onward. Conventionaldesigns accomplish this by clamping with threaded fasteners. Anexemplary conventional design is illustrated in FIG. 8, in which theheater assembly 200 includes a mica heater layer 202 connected to anenergy source by electrical leads 204, a rigid backing plate 206adjacent to but separated from one side of the mica heater layer 202 byan electrically nonconductive insulating layer 208, and a thermallyconductive support layer 210. The heater assembly 200 is held togetherby a retainer, such as threaded fasteners 212. The size of these heaterassemblies 200 is typically rather large in the dimension perpendicularto the plane of the heater layer 202 due to minimum required threadengagement.

By replacing the threaded fasteners with a tension member and spring,the thickness of the package can be reduced over that required forthreaded fasteners. An additional benefit of using a spring to clamp themica heater together is the ability to maintain clamp force afterrepeated thermal cycles and for years of storage. Conventional fastenerswith short length in tension are prone to losing tension as the portionsin compression thin due to time or thermal cycling.

A thin profile mica heater assembly in accordance with aspects of thepresent invention is illustrated in FIGS. 9-12. Referring to FIGS. 9-12,the thin profile mica heater assembly 120 includes one or more retainingmechanism 122 to securely hold the various layers of the heater assembly120. The retaining mechanism 122 may be any size and shape. Asillustrated in FIGS. 9-12, the retaining mechanism 122 may have a J-hookconfiguration, which includes an extended portion 124 that extendsthrough each component of the heater assembly 120 and an end portion 126configured to apply a compressive force on the stack of components. Inanother embodiment, the retaining mechanism 122 may include a separateE-clip style fastener rather than the J-hook configuration, for example.The retaining mechanism 122 may be coupled to a biasing member 142(e.g., a spring) to provide the compressive force.

The heater assembly 120 includes a thermally conductive layer 130, whichis configured to make contact with the one or more actuators 100 and/orwith corresponding conductor sections 22 when the fuel units areinserted in the cavity 74 and the actuators 100 are in the second state.The thermally conductive material layer 130 is in contact with supportlayer 132. The electrically nonconductive support layer 132 is incontact with the resistive heater layer 134. The resistive heater layer134 includes one or more electrical contact pads 152A, 152B configuredto receive current from one or more power sources. Thermal energy fromthe resistive heater layer 134 is transferred through the support layer132 (e.g., a mica layer) to the thermally conductive layer 130, which iscoupled to a fuel unit 60, 86 and/or actuator 100 in order to transferheat generated by the resistive heater layer 134 to the fuel unit 60, 86and/or actuator 100.

The heater assembly 120 further includes an electrically nonconductivelayer 136. Layer 136 can be made from mica. Layer 136 is coupled to athermally insulative layer 138. Thermally insulative layer 138 isconfigured to limit thermal energy from passing therethrough. The heaterassembly 120 further includes a backing plate 140 for providing supportto the heater assembly 120. A spring clamp layer 142 is configured to bebound by the retaining mechanism 122 in order to secure the variouslayers of the heater assembly 120 in a prescribed manner.

As shown in FIGS. 10 and 12, a variety of mechanisms 150 may be formedor otherwise imparted into each of the component layers (e.g., layers130-142) to enable securing of the layers 130-142 to form the heaterassembly 120. In one embodiment, the mechanism 150 is in the form of aslot, wherein each component layer 130-142 may be slidingly mounted toform the heater assembly 120, as illustrated in FIG. 10. In anotherembodiment, the mechanism 150 is in the form of a circular void formedor otherwise imparted into each of the component layers (e.g., layers130-142) to enable securing of the layers 130-142 to form the heaterassembly 120, as illustrated in FIG. 12. In the embodiment, illustratedin FIG. 12, each layer 130-142 is placed over or under an adjacent layer130-142 to foul' the heater assembly 120.

It should further be noted that layers 130-134 are generally formed ofsimilar size and shape. In particular, layer 134 includes a portion onwhich electrical contact pads 152A, 152B are disposed. In contrastlayers 136, 138 and 140 include a void 154 that corresponds to thelocation of the contact pads 152A, 152B to provide space for attachingelectrical leads.

All references cited herein are expressly incorporated herein byreference in their entireties. To the extent publications and patents orpatent applications incorporated by reference contradict the disclosurecontained in the present specification, the present specification isintended to supersede and/or take precedence over any such contradictorymaterial.

It will be understood by those who practice the invention and thoseskilled in the art that various modifications and improvements may bemade to the invention without departing from the spirit of the disclosedconcept. The scope of protection afforded is to be determined by theclaims and by the breadth of interpretation allowed by law.

What is claimed is:
 1. A hydrogen gas generator comprising: a housingincluding a plurality of sidewalls and a rear wall, wherein theplurality of sidewalls and rear wall form a cavity configured to receiveone or more fuel units; and a heater assembly configured to be at leastpartially housed within the cavity, the heater assembly comprising asupport member, at least one heating element capable of convertingelectrical to thermal energy, and at least one temperature-sensitiveactuator, the at least one heating element and temperature-sensitiveactuator being disposed in a stacked arrangement with respect to thesupport member, and said actuator capable of transforming from a firstdimensionally retracted state to a second dimensionally expanded statewhen heated by the at least one heating element, wherein the at leastone actuator is in the first state when a temperature of the at leastone actuator is below a first prescribed temperature and the at leastone actuator is in the second state when a temperature of the at leastone actuator is above a second prescribed temperature that is equal toor higher than the first prescribed temperature, and wherein at leastone of the at least one heating element or the at least one actuator isdisplaced closer in proximity to the one or more fuel units when the atleast one actuator is in the second state than when the at least oneactuator is in the first state.
 2. The hydrogen gas generator of claim1, wherein in the second state the at least one heating element is inconductive thermal communication with at least a portion of the one ormore fuel units.
 3. The hydrogen generator of claim 1, wherein in thesecond state, the temperature-sensitive actuator is in contact with andin conductive thermal communication with at least a portion of the oneor more fuel units.
 4. The hydrogen generator of claim 1, wherein in thesecond state, the heating element is in contact with at least a portionof the one or more fuel units.
 5. The hydrogen gas generator of claim 1,further including a front panel configured to engage the plurality ofsidewalls in order to close the housing.
 6. The hydrogen gas generatorclaim 5, further comprising an interlock system, such that when the atleast one temperature-sensitive actuator is in the second state, thefront panel is more difficult to disengage from the plurality ofsidewalls than when the at least one actuator is in the first state. 7.The hydrogen gas generator of claim 1, wherein the at least onetemperature-sensitive actuator is a bimetallic element.
 8. The hydrogengas generator of claim 7, wherein the first prescribed temperature is200 degrees Celsius and the second prescribed temperature is 250 degreesCelsius.
 9. The hydrogen gas generator of claim 1, wherein the at leastone heating element and at least one thermal actuator are in thermalcommunication with one another.
 10. The hydrogen gas generator of claim1, wherein the heater assembly extends between two or more fuel cells.11. A method for heating a fuel unit provided in a hydrogen gasgenerator of claim 1, the method comprising: receiving one or more fuelunits in a cavity of the housing; applying electrical energy to the atleast one heating element, thereby generating heat that is conductivelytransferred to at least one adjacent temperature-sensitive actuator;heating the at least one temperature-sensitive actuator above the firstprescribed temperature to the second prescribed temperature, therebycausing the actuator to be in the second dimensionally expanded state;and contacting one of the at least one heating element or the at leastone actuator to the one or more fuel units for selectively heating theone or more fuel units.
 12. The method of claim 11, wherein the at leastone actuator is operative to move between the first state and the secondstate upon reaching one of the first and second prescribed temperatures.13. The method of claim 11, wherein the at least one actuatormomentarily snaps between the first state and the second state uponreaching one of the first and second prescribed temperatures.
 14. Themethod of claim 11, wherein the at least one actuator is a bimetallicelement.
 15. The method of claim 14, wherein the first prescribedtemperature is 200 degrees Celsius and the second prescribed temperatureis 250 degrees Celsius.
 16. A hydrogen gas generator comprising: ahousing including a plurality of sidewalls and a rear wall, wherein theplurality of sidewalls and the rear wall form a cavity configured toreceive one or more fuel units; a heater assembly comprising a supportmember, at least one heating element capable of converting electrical tothermal energy, and at least one temperature-sensitive actuator, eachspatially positioned in an array with respect to one another, the atleast one heating element and temperature-sensitive actuator beingdisposed adjacent to one another and said actuator capable oftransitioning from a first dimensionally retracted state to a seconddimensionally expanded state when heated by the at least one heatingelement, wherein the at least one actuator is in the first state when anactuator temperature is below a first prescribed temperature and the atleast one actuator is in the second state when an actuator temperatureis above a second prescribed temperature that is equal to or higher thanthe first prescribed temperature, and wherein at least one of the atleast one actuator and the at least one heating element is disposedcloser in proximity to the one or more fuel units when the at least oneactuator is in the second state than when the at least one actuator isin the first state.
 17. The hydrogen gas generator of claim 16, whereinin the second state, the at least one actuator is in contact with atleast a portion of the one or more fuel units.
 18. The hydrogen gasgenerator of claim 16, wherein in the second state, the at least oneheating element is in contact with at least a portion of the one or morefuel units.
 19. The hydrogen gas generator of claim 16, furtherincluding a front panel configured to engage the plurality of sidewallsin order to close the housing.
 20. The hydrogen gas generator claim 19,wherein when the at least one actuator is in the second state, the frontpanel is more difficult to disengage from the plurality of sidewallsthan when the at least one actuator is in the first state.
 21. Thehydrogen gas generator of claim 16, wherein the at least one actuator isa bimetallic element.
 22. The hydrogen gas generator of claim 21,wherein the first prescribed temperature is 200 degrees Celsius and thesecond prescribed temperature is 250 degrees Celsius.
 23. The hydrogengas generator of claim 16, wherein the at least one heating element andat least one thermal actuator are in thermal communication with oneanother.
 24. The hydrogen gas generator of claim 16, wherein the heaterassembly is mounted to at least one sidewall of the housing, such thatthe support member is adjacent to the at least one sidewall.